Corrugating machine



April 9, 1935. L. J. ROGERS CORRUGATING MACHINE Filed June 21, 1934 3 Sheets-Sheet l awe/111 M Lou/s Paye s L. J. ROGERS 1,997,122

CORRUGATING MACHINE Filed June 21, 1934 3 Sheets-Sheet 2 April 9,1935.

II I21 III I #uHb.) llllll II 4 g E w C I @K TR April 9, 1935. J. ROGERS 1,997,122

I CORRUGATING MACHINE Filed June 21, 1934 I5 Sheets-Sheet 3 .5 Z 27 -i 25 g &

III

Patented Apr. 9, 1935 UNITED STATES PATENT OFFICE 9 Claims.

This invention relates to corrugating dies and particularly to a corrugating die for forming corrugations in wide heavy gauge sheet metal stock.

Heretofore in the corrugation of steel sheets of comparatively heavy gauge, the practice has been to form the corrugations successively between 21. single pair of dies, withdrawing the sheet after each bend and turning and reinserting it for the succeeding bend. This method is followed largely because of the fact that in forming corrugations, a substantial width of the stock material transversely of the corrugations must be provided for forming the side walls thereof, either by stretching the sheet or permitting free travel of the outer margins to compensate for reduced overall width. This is especially true when the corrugations are comparatively deep and the stock is heavy gauge, as lateral travel of the sheet stock .is then so excessive. and stretching of the stock so difficult that successive forming operations are necessary. The power requirement for a press of suflicient strength and power to stretch such sheets or effect lateral travel against frictional resistance of the forming dies are in excess of that generally required in the mills, and successive forming operations are utilized also becauseof such limitations of equipment.

One of the principal objects of the present invention is to corrugate such sheets at a single operation and with such reduced power require-.

ments that generally used presses may be utilized therefor.

Another object is to effect free travel of the sheet portions of the stock during the corrugating operation so as not to stretch the metal in any manner.

Still another object is to corrugate the sheet by utilizing only a bending force as distinguished from stretching, upsetting and like forces.

A more specific object is to grip aligned opposite face portions of the sheet firmly preparatory to the corrugating operation and to retain the same firmly gripped during the forming operation so that relative movement between the surface portions of the sheet engaged by the dies and the dies engaging such portions is eliminated.

A correlative-object is to effect travel of the dies during forming with the respective sheet portions engaged-in a direction transversely of the corrugations to be formed.

Other objects and advantages will become apparent from the following specification wherein reference'is made to the drawings, in which Fig. 1 is a side elevation, partly in section, of

a part of a die combination embodying the principles of the present invention;

Fig. 2 is a top plan view of the lower set of dies of Fig. 1, taken on a plane indicated by the line 22 of Fig. 1; l

Fig. 3 is a cross sectional view taken on a plane indicated by the line 3-3 of Fig. 1;

Fig. 4 is a diagrammatic top plan view of the lower set of dies, illustrating the closed position thereof; and

Fig. 5 is a diagrammatic side elevation of the dies when in the closed position illustrated in Fig. 4,

The apparatus comprises a pressure head plate I and base plate 2 which are movable relatively toward and away from each other, preferably by connecting the head plate I to the usual hydraulic press, such as is commonly used in forming operations. The head and base plates are provided, at their corner portions, with upright aligning posts 3 for maintaining the plate in alignment with each other as they are moved together and apart. Carried by the head plate I, on longitudinally extending skid tracks 4, disposed along each side of the plate I, are a plurality of separate dies, designated 5 to 8 respectively, which are movable up and down with the plate 2. correspondingly, on the base plate 2, are dies It] to I3 inclusive which, in the order enumerated, cooperate respectively with the dies 5 to 8 in order. The dies of theupper set are in alignment with the corresponding dies of the lower set and are maintained in this alignment at all times, both before and during the formation operation.

In the form illustrated in Fig. 1, only slightly more than one half of the entire die combination is illustrated, the other half being symmetrical to the part shown and corresponding therewith in form and function and the dies 5 and Ill being the central dies of the combination.

The two dies 5 and I0 are secured in fixed position on the respective plates I and 2. The remaining dies of each set, however, are so arranged that they may be moved toward the dies 5 and II) respectively. Referring particularly to the dies 6 and H, as illustrative of the remainder of the movable dies, each is provided with segmental rollers H5. The rollers l6 are of constant radius and are rotatable about an axis extending parallel to the direction in which the corrugations to be formed by the dies will extend, which direction is herein referred to as laterally" for convenience in description.

Referring to Fig. 3, it will be noted that each of being equal-to the height of the side wall of the the dies carries a plurality of rollers, the rollers of adjacent ones of the dies of each set being staggered with relation to those of the other set so as to more readily accommodate a larger number. The rollers are preferably mounted in the die blocks by providing slots I1, the walls of which define flangesor sliding surfaces snugly embracing the side faces of the segmental rollers. At the upper ends of the slots-l] are arcuate bearing surfaces [8 which receive and engage complementary bearing surfaces l6a on the cooperating ends of the rollers I6. Suitable bolts l9 are provided to retain the rollers with their bearing surfaces l8 and I 8a in proper engagement witheach other.

It should be noted that the bolts l9 are not for the purpose of transferring the stress from the die blocks to the rollers, but merely hold the rollers with their bearing surfaces I80. in approximate alignment with the bearing surfaces I8 so that proper engagement thereof is effected when pressure is applied to the dies.

In order that the rolling surfaces I8 of the dies be readily accessible for purposes of machining, the portions of the dies, between adjacent rollers l6, are removable. These portions, indicated at 20, may be secured to the remainder of the die blocks by suitable bolts 2|.

In order to prevent the segmental rollers from rotating out of their proper position, track elements 22 and 23 are provided respectively on the head and base plates, these elements extending laterally of the plates and being provided with transverse or lateral depressions, such as indicated at 24. correspondingly, on the rollers l6 are suitable lugs 25 which engage these depressions and thus prevent the rollers from skidding or kicking out of their proper relatively rotated positions in case the frictional resistance between their track engaging surfaces and the tracks is not sufficient to retain them properly positioned.

All of the dies of each set, except the central stationary dies 5 and l0,are thus provided with segmental rollers so that they can travel inwardly toward the dies 5 and It in a direction transversely of the corrugations to be formed concurrently with the movement of the sets toward each other for the forming operation.

In the form illustrated, the dies 6 and 8 of the upper set engage the surface portions of the stock S which are to form the inner surfaces of the engage the surface of the stock which is to form the outer surface of the crests of the corrugations. Correspondingly, in the'lowe'r set of dies, the dies II and I3 form the outer surfaces of the crests of the corrugations while the dies l0 and I2 form the inner surfaces. The dies of the respective sets are spaced from the remaining dies in the same set, the distance therebetween corrugation to be formed. For example, the distance designated X in Fig. 1 is equal to the height of the side wall of the corrugation to be formed and is accordingly the distance between the dies 6 and I when they initially engage the stock S.

As explained in the objects, it is desirable that the stock be gripped'by opposite aligned dies on both aligned opposite surface portions and be held. firmly therebetween preparatory to and during the forming operation so that there is no relative travel between the portion of the stock S so engaged and the dies by which engaged. For example, that portion of the stock S engaged by the die 6 and the plate 26 of the the H is maintained in fixed position relative to the engaging faces of said die 6 and plate. Consequently, there is no travel of the engaged portionof the sheet in a direction transversely of the corrugations relative to. the aligned dies that is the face of the die 6 and the face of the plate 26, by which the portion is engaged. The same is true of all other portions of the sheet similarly engaged. Thus, opposite aligned dies may travel together in a direction transversely of the corrugations while maintaining firm gripping relation with the stock as the overall length of the sheet transverselyof the corrugations shortens consequent upon forming.

For effecting this result, the dies which. form the outer surface of the crest of the corrugations,

'for example the dies 5, 1, 8 and I3 are provided with face plates 26, coextensive with the respective stock surfaces to be engaged by the dies with which the plates 26 are associated. The face plate 26 of each die is mounted on suitable posts 21 which extend into the die block and are slidable axially therein so that the plate may move toward and away from the face of the die with which associated while maintained in alignment with the cooperating die of the opposite set. Thus when the sheet isfirst engaged, it is engaged between a rigid fixed die face, such as the die 6. on one face portion and on the aligned opposite face portion is engaged by the face plate 26 on the die H. the sheet and held firmly in contact therewith by virtue of springs 28 with suflicient pressure to provide a vise-like grip between the sheet and opposite aligned dies, both preparatory to and during the forming operation. The plates 26 are so mounted that as downward pressure is applied on the head plate 2 by the press, they seat on the dies with which associated, compressing the springs 28 which continue exerting gripping pressure, thus presenting final surfaces posi- The face plate 26 is forced against tioned relative to the adjacent dies to form the outer crests of the corrugations.

Since all except the central dies of each set are mounted on rollers they move inwardly toward the dies 5 and II! respectively due to the pull of the sheet stock as the movable head. and base plates are brought together. This action would continue unassisted until the portions X of the stock between adjacent dies were disposed at an angle of at least 45 to the horizontal, thus compensating for the shortening of the overall length of the sheet due to turning the portions X at an angle to the remainder of the sheet. Continued force of the upsetting press after this point was reached, however, would draw the dies closer together but would stress the metal and require disproportionate pressure. Consequently, it is desirable that the dies be positively moved toward each other into substantially edge to edge abutting relationship during the forming operation so that the power required is only the small amount necessary to bend the metal at right angles to its plane around the edge of the dies.

For this purpose, suitable hydraulic presses 60 and 30' are provided at each end of plates 2 and l respectively. Referring illustratively to the press 30, a rigid operating lever, which may comprise a part of the piston 3| of the hydraulic press, is secured to a pivoted rocker arm 32 so as to rock the same to and from in a direction transversely of the corrugations consequent upon reversal of the operation of the hydraulic press. Operating rods 36, 31 and 38 are pivotally connected at one end to the rocker arm 32, the opconfiguration of the sheet.

posite ends thereof being connected to dies ll, l2 and I3 respectively in the order named. The points of connection of the levers or rods 36 to 38 respectively with the rocker arm are different distances from the pivotal axis 40 of the rocker arm, depending on the distance the dies connected thereto are to be moved. Therefore, the rods travel in a direction toward the die It different distances consequent upon rocking of the arm 32 theretoward. The die travels the least distance and the die l3 the greatest distance and any intermediate dies progressively greater distances than the die II from the innermost to the outermost die. For example, the die ll must travel only the distance X. In order for the die I 2, however, to be brought into substantially edge to edge contact with the die II it must compensate for two spaces of X distance each, as the die I I will have travelled the distance X to the left. Correspondingly, the dies [3 must travel to compensate for three such spaces and therefore must move three times the distance of the die II, and so on, depending upon the number of dies provided. Similar operating means are provided for the upper dies and for dies to the other side of the stationary dies.

As the plate 2'descends on the forming stroke, the presses 30 and 30 are operated so that the dies move inwardly in a direction transversely of the corrugations toward the die In, concurrently with the downward movement of the upper set of dies, the stock portions being held firmly meanwhile by .the aligned die faces by which engaged. Thus when the final forming position is reached, all of the dies in each set lie in substantially edge to edge abutting relationship with the other dies in the same set andform substantially a single continuous die face on each side of the sheet conforming to the final The plates 26, of course (move toward the dies bywhich carried) as the plate 2 lowers, and finally seat thereon, compressing the springs 28 and lying in engagement with the outer-surfaces of the crests of the corrugations thus formed. When this operation is completed, the upper dies are raised from the lower while all the dies of each set remain inedge to edge abutting relation with each other.

As sets of dies are separated, the springs 28 oper-.

ate to move the plates 26 relatively away from the dies with which associated and .since they are on the outer surface of the crestsof the corrugations, they free the formed sheet from the dies. Suitable stops 2Ia are provided on each of the posts 21 to limit the movementof the plates 26 away from the dies by which carried. These stops are positioned to stop movement of the plates in a position such that the operating faces of all dies of each set lie in the same plane when the dies are fully separated; Thus the sheet is not only freed from the dies of each set but is disposed between two parallel plane surfaces from which it can be readily removed either enddies of the lower set are If excessively heavy sheets are to be operated, however, the movable plates 26 may be mounted on hydraulically operated plungers or posts, wherein each plate is carried on posts operating in a chamber in the die block, the chambers, in turn, being provided with inlets in communication with a constant pressure tank such as commonly provided insteel forming mills. Thus the plates 26 may be forced hydraulically firmly into engagementwith the sheet and, as the dies are brought together, the liquid is expelled from the chambers into the constant pressure tank which is of adequate capacity to receive this liquid with-- out an appreciable change in the pressure. Correspondingly, when the dies, are separated, the

liquid would again flow into the chambers from the constant pressure tank and lift the plates 26 in the same manner as and as equivalents of the springs.-

It is apparent from the foregoing description that the die combination, above described, is effective for the purpose for which provided and may be changed in detail depending upon the configuration of the particular sheet to be formed Y without departing from the principles embodied and corresponding dies of opposite sets having operating face portions aligned with each other,

means for effecting pressure contact between the from each other, means mounting the dies of each set for movement in a direction transversely ofthe corrugations, and means operable for moving the corresponding dies of each set in a direction transversely to the corrugations while the said aligned operating faces remain in fixed position relative to the respective surface portions of the stock engaged thereby and in fixed position rela tive to each other.

2. In an apparatus for corrugating metal sheets,

sets of complementary dies, the dies of each set.

being spaced apart in the direction transversely of the corrugations to be formed a distance sufiicient to provide metal stock for the side walls of the corrugations, and operating faces of corresponding dies of opposite sets being aligned with each other, means for effecting engagement of aligned operating faces of the dies with the stock and for retaining the surface portions of the stock engaged by the said aligned die faces in fixed position relative to the aligned die faces by which engaged both preparatory to and during the forming operation, means mounting the sets of dies for movement relatively toward-and away from each'other, and means mounting the dies of each set for movement in a direction transversely of the corrugations and into edge to edge relationship to each other, whereby the sheet is finally formed between two. substantially continuous walls conforming to the corrugated surfaces desired.

3. In a device of the character described, complementary sets of dies, corresponding dies of said sets being aligned with each other, means operable to move the sets of dies toward and away from each other, movable face plates mounted on and providing the operatingface of certain dies of each set, means operable to yieldably force said face plates firmly against face portions of the stock overlying the dies by which the plates are carried, while the aligned opposite face portions of the stock are engaged by complementary dies of the opposite set, whereby the sheet is firmly gripped preparatory to the forming operation and said face plates may move toward the dies with which associated while retaining said pressure as the sets of dies are moved toward each other and the sheet is held thereby both before and during the forming operation in fixed position relative to the dies by which so engaged, and means mounting the dies of each set for movement with the stock to be formed transversely of the corrugations during the forming operation.

4. In a device of the character described, complementary sets of dies, corresponding dies of said sets being aligned with each other, means operable to move the sets of dies toward and away from each other, movable face plates mounted on certain of the dies of each set and providing the operating faces thereof, means operable to yieldably force and retain said face plates firmly against one face of the stock while .the aligned opposite face portions of the stock are engaged by complementary dies of the opposite set, whereby the sheet is firmly gripped preparatory to and during the forming operation and said face plates may be moved toward the dies with which associated while retaining said gripping pressure as the sets are moved toward each other, and the sheet is held both before and during the forming operating in fixed position relative to the dies by which engaged, said face plates being mounted on the dies which engage the face portions of the metal forming the outer crests of the resulting corrugations. v

5. In an apparatus for corrugating metal sheets, parallel spaced head and base plates movable toward and away from each other, sets of complementary dies respective to said plates and disposed therebetween, rollers supporting the dies on said respective plates, the rolling axes of said rollers being disposed transversely of the direction of travel, during the forming operation, of the sheet stock to be formed, whereby the dies of each set may roll toward each other as the overall length of the stock is reduced during the forming operation, corresponding dies of the opposite sets engaging the stock on aligned opposite face portions and firmly gripping the stock preparatory to and during the forming operation.

6. In an apparatus for corrugating metal sheets, sets of complementary dies, said sets being movable relatively toward and away from each other, operating faces of corresponding dies of the opposite sets being aligned with each other and being engageable with aligned opposite face portions of the sheet to .be corrugated, means for effecting said engagement and for maintaining said engagement with sufilcient pressure contact to retain the sheet face portions so engaged by said aligned die faces in fixed position relative to the aligned die faces by which engaged during the forming operation, and means mounting the aligned corresponding dies of opposite sets for travel transversely of the corrugations while the said aligned die faces are in contact with andin fixed relation to the respective aligned face portions of the sheet initially engaged thereby, whereby shortening of the overall dimension of the sheet in the direction transversely of the corrugations is permitted without stressing the metal and without movement of any surface of the sheet initially engaged by said aligned die faces relative to the die faces by which engaged.

I. In an apparatus for corrugating metal sheets,

sets of complementary dies, said-sets being movable relatively toward and away from each other, die faces of corresponding dies of the opposite sets being aligned with each other and being engageable with aligned opposite face portions of the sheet to be corrugated, means for effecting and maintaining engagement between said aligned die faces and the aligned opposite face portions of the sheet preparatory to and during the forming operation respectively with sufiicient pressure to retain the sheet face portion so engaged by the die faces in fixed position relative to the aligned die faces by which initially engaged, means mounting the corresponding dies of opposite sets for travel in a direction transversely of the cor rugations while the faces thereof are in fixed relation to and contact with the initially engaged aligned portions of the sheet, and means operable to force themes of each set relatively toward each other transversely of the corrugations during movement of the, sets of dies toward each other.

8. In an apparatus for corrugating metal sheets, parallel spaced head and base plates movable toward and away from each other, sets of complementary dies respective to the plates and disposed therebetween, rollers supporting the dies on said respective plates, the rolling axes of said rollers being disposed transversely of the direction of travel during the forming operation of the sheet to be formed, whereby the dies of each set may roll toward eachother to compensate for shortening of the overall length in the direction transversely of the corrugations of the stock during the forming operation.

9. In an apparatus for corrugating metal sheets, a

parallel spaced head and base plates movable to- .ward and away from each other, sets of complementary dies respective to said plates and disposed therebetween, means mounting the dies on said respective plates for movement in the direction of travel, during the forming operation, of the sheet stock to be formed, whereby the dies of each set may move toward each other as the overall length of the stock is reduced during the forming operation, corresponding dies of the opposite sets engaging the stock on aligned opposite face portions and firmly gripping the stock preparatory to and during the forming operation.

LOUIS J. ROGERS. 

